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Advanced manufacturing

Arup provides solutions for manufacturing plants, industrial processes, distribution centres and logistics, as well as specialised services including seismic design, fire engineering and sustainability consulting.

Arup provides solutions for manufacturing plants, industrial processes, distribution centres and logistics, as well as specialised services including seismic design, fire engineering and sustainability consulting.

Manufacturing in 2050 will look very different from today and will be virtually unrecognisable from that of 30 years ago. A broad range of complex and interconnected factors are driving a major transformation in the sector.

The industry is working to become more sustainable, decarbonise and transform to a Circular Economy model while new technologies and Artificial Intelligence are modifying the profile of the workforce, changing relationships across the supply chain, manufacturing process, and customers.

Automotive facilities

Factories increasingly need to be significantly more responsive to rapidly changing market dynamics and operational environments in the future, adapting physically to supply chain disruptions and variations, new product lines, machinery and equipment.

Automotive facilities typically set up to maximise economy of scale for a limited range of vehicle models are now adapting to the smart factory model where equipment is flexible and readily adapted to manufacture multiple models within the same factory.

Jaguar Land Rover

Jaguar Land Rover Engine Manufacturing Centre, i54, UK

The facility is JLR’s first dedicated engine manufacturing plant in the UK, incorporating both high tolerance machining and assembly halls in one building. The 200,000m2 development has the capability of producing 600,000 engines a year. Arup met JLR’s performance and sustainability objectives by setting high standards of fabric and building features which included natural ventilation, day lit office and the largest rooftop PV array in the UK

Find out more about our work with Jaguar

National Automotive Innovation Campus

National Automotive Innovation Campus

The National Automotive Innovation Centre (NAIC), is a centre for world-leading research in developing new automotive technologies aimed at reducing CO2 emissions and dependency on fossil fuels.

NAIC has been designed to achieve a minimum BREEAM ‘Excellent’ rating. Environmental sustainability has influenced the choice of materials and construction methods, including the in-situ concrete frame and glulam roof structure, which is renewably sourced with low embodied energy.

Daimler

Daimler, Russia

Placing all of the production steps under the one roof assisted in creating shorter paths and faster, more direct communications during production. This philosophy was also reflected in the architecture; glass walls serve as a connecting feature and make the spaces between the workplaces in administration and production transparent. Driverless transportation systems convey the bodies between production subsections, and automated shopping cart systems are also used in assembly.

Find out more about our work with Daimler

Rolls Royce

Rolls Royce, UK

Rolls-Royce’s new-build 28,000m2 facility will house a range of manufacturing and production facilities and a wide range of specialist process systems.

Arup was appointed as multidisciplinary engineering designers, to provide fully-integrated engineering solutions in response to complex business needs, whilst maintaining the integrity of a landmark architectural design Working closely with the architect, we prepared all engineering designs from a fully integrated BIM, enabling the client to test and understand all design concepts throughout the early design process.

Food and drink and consumer goods

Manufacturing processes, especially within the food and drink sector, are dominated by the need for rapid response in terms of production and product development, coupled with the desire for lean production to minimise costs.

Working with breweries, distilleries & wineries

As part of Molson Coors’ investment to modernise Britain’s Biggest Brewery, Arup provided strategic advice and project management services. Our site masterplan enabled the business to improve efficiency by selling land, create a smaller site footprint and increase beer production capacity.


By recognising the value that can come from coherent, well-structured supply chains and processes, our consultants focus on working with you to find sustainable solutions. The benefits include operations that meet economic, environmental and social objectives; reduced operational and project risk and developments that deliver their operational requirements.

Over the last decade, we have helped our clients achieve revenue growth, reduce production line unit costs, improve speed to market and exploit the opportunities presented by operating in or competing with lower cost regions and markets.

This is Clarks’ sole distribution facility servicing orders in the US and Canada, It is capable of handling volumes of up to 50M pairs of shoes and improves operational performance. The facility received LEED Gold certification. This is Clarks’ sole distribution facility servicing orders in the US and Canada, It is capable of handling volumes of up to 50M pairs of shoes and improves operational performance. The facility received LEED Gold certification.

Mingzhu Rice Winery, South China

Clarks US logistics centre handles 50m pairs of shoes annually. We were hired to advise on increasing capacity, focusing on the material handling system and the building design and construction. As well as design, we also provided project management, commissioning and scheduling services.

In Mexico, our team worked with Proctor & Gamble's Planta Milenio - the first fully sustainable manufacturing facility in Latin America. Our integration of a flexible infrastructure enables the facility and the manufacturing process to adjust to newer technologies and production strategies. At the same time, it was important to develop an improved user experience for staff without compromising funtional capabilities.

Aerospace

Arup have been involved with a number of high profile aerospace projects where we have assisted clients achieve and exceed expectations to meet their immediate and future requirements. Within aerospace, manufacturing processes are commonly of a higher complexity and lower volume, requiring high quality sustainable environments. The outcomes have led to low energy facilities with reduced operational costs as a result of integrated process and building elements. Other benefits from our advisory services have included operational needs, process material logistics and delivering rapid responses to highly technical issues.

We worked with Airbus to maximise capacity at its Bristol plant

Working with Airbus

Working with AMRC Cymru, we undertook the design mission to enable the Airbus 'Wing of Tomorrow' programme, focused on designing aircraft wings using advanced metallic or composite materials. A flexible floor plate was incorporated utilising a grid of flexible fixing points to replicate a range of manufacturing cells from the Airbus production facility.

At Airbus' Bristol plant, we advised on how to re-organise the production processs and to improve the scheduling of stringers to maximise capacity and match customer requirements for 'wing sets' without large stock buffers. The result was the creation of a workable expansion plan highlighting the developmental steps required as production volume increased.


Discover how our team can help

You can access our expertise through regional consultants around the world. Wherever you’re based, we can help you look beyond your sector to explore new sources of inspiration and identify opportunities for growth.